One-piece sloped ceiling baffle

ABSTRACT

A one-piece, sloped baffle includes a generally cylindrical central opening having a central axis extending between an open circular end and an open elliptical end. A plane defining the open circular end is perpendicular to the central axis. A plane defining the open elliptical end is at an oblique angle relative to the central axis. The baffle further includes an opening extending between the ends and a pair of opposing edges substantially parallel with the central axis and on opposite sides of the opening. First projections are positioned on opposite sides of the opening and aligned with the opposing edges. Second projections are positioned on opposite sides of the opening at a radial distance from the first projections. The baffle further includes a plurality of grooves that extend circumferentially around an inner surface of the baffle.

PRIORITY INFORMATION

This is a Divisional Application of co-pending U.S. patent application Ser. No. 13/467,208, filed May 9, 2012, which claims priority to U.S. Provisional Application Ser. No. 61/486,128 filed May 13, 2011. The disclosure of the above-identified prior U.S. Patent Applications, in their entirety, are considered as being part of the present U.S. Patent Application, and thus, are incorporated herein by reference.

FIELD OF THE INVENTION

The present disclosure relates to baffles for lighting fixtures, and, more particularly, to one-piece, sloped baffles for lighting fixtures installed in a sloped ceiling.

BACKGROUND

Prior sloped baffles used in lighting fixtures include a two-piece design that requires the precise alignment of the two pieces and clamping together of the same prior to installation of the baffle into a lighting fixture. Alignment of the two pieces is difficult and can result in an imperfect alignment of internal features of the baffle, which negatively impacts the baffle's ability to diffuse light uniformly and negatively affects the aesthetics of the baffle. Additionally, the two-piece design includes two vertical seams that also negatively affects the aesthetics of the baffle. The present disclosure addresses these and other problems.

BRIEF SUMMARY

The present disclosure describes a one-piece, sloped baffle for use in a lighting fixture installed in a sloped ceiling. The disclosed one-piece, sloped baffle is formed using an injection molding process that results in the one-piece, sloped baffle having an opening or vertical slot that extends the entire height of the baffle. The vertical slot can be spread apart or widened after the molding of the one-piece, sloped baffle, which is necessary to remove the one-piece, sloped baffle from a portion of the mold (e.g., core portion of the mold) without damaging an internal feature (e.g., at least one groove) of the one-piece, sloped baffle. The widening of the vertical slot is a necessary step because the internal feature prevents the one-piece, sloped baffle from being removed from the mold otherwise.

The vertical slot also results in an assembled one-piece, sloped baffle having only one seam as compared to two seams in the prior art two-piece baffle. The one seam can be advantageously placed along the shortest vertical portion of the one-piece, sloped baffle to minimize its negative impact on the aesthetics of the one-piece, sloped baffle when installed. The vertical slot also reduces the number of parts and necessary steps when assembling the one-piece, sloped baffle. Specifically, fasteners such as spring clips or clamps are only needed to hold the one seam together as compared to the two seams in the prior art two-piece baffle. Additionally, the one-piece design eliminates the need for having to align two baffle pieces prior to assembling the same with spring clips or clamps.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings.

FIG. 1 is a perspective view of a one-piece, sloped baffle;

FIG. 2 is a front view of the one-piece, sloped baffle of FIG. 1;

FIG. 3 is a top view of the one-piece, sloped baffle of FIG. 1;

FIG. 4 is a side cross-sectional view of the one-piece, sloped baffle of FIG. 1;

FIG. 5 is a partial top cross-sectional view of the one-piece, sloped baffle of FIG. 1;

FIG. 6A is an exploded perspective view of a baffle assembly including the baffle of FIG. 1, a trim ring, and a fastener;

FIG. 6B is an assembled perspective view of the baffle assembly of FIG. 6A;

FIG. 7 is a flow chart of a method of forming a one-piece, sloped baffle; and

FIG. 8 is a flow chart of a method of assembling a one-piece, sloped baffle assembly.

While the description is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the description is not intended to be limited to the particular forms disclosed. Rather, the description is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the description as defined by the appended claims.

DETAILED DESCRIPTION

Referring generally to FIGS. 1-5, a one-piece, sloped baffle 10 includes a generally cylindrical central opening 20 having a central axis 30 extending between an open circular end 50 and an open elliptical end 60. The one-piece, sloped baffle 10 is configured to be used in a lighting fixture (not shown) installed in a sloped structure (e.g., a sloped ceiling) (not shown) or orientation, where the sloped structure is offset from horizontal. It is contemplated that the one-piece, sloped baffle 10 can be used in lighting fixtures installed in non-sloped structures. The one-piece, sloped baffle 10 can be formed from a variety of materials, such as, plastic or metal. A few non-limiting examples of suitable types of plastics include glass-filled polyester, thermosetting plastics, phenolic plastics. Examples of lighting fixtures installed in sloped ceilings suitable for use with the baffles of the present disclosure are shown and described in U.S. Pat. No. 4,729,080, which is hereby incorporated by reference herein in its entirety.

The open circular end 50 is defined by a plane that is perpendicular to the central axis 30. The open elliptical end 60 is defined by a plane that is at an oblique angle, α, relative to the central axis 30. The oblique angle, α, of the plane defining the open elliptical end 60 of the baffle is designed to substantially match the slope of the ceiling or structure containing the lighting fixture (not shown) including the one-piece, sloped baffle 10. The oblique angle, α, can be any angle, such as, for example, any angle between about five and about seventy-five degrees. For another example, the oblique angle, α, can be any angle between about ten and about thirty degrees.

The one-piece, sloped baffle 10 has an outer generally cylindrical surface 15 (best shown in FIG. 1) that extends from the open circular end 50 to the open elliptical end 60. The open elliptical end 60 includes an elliptical flange 18 that has a generally elliptical shape (best shown in FIG. 1).

The outer generally cylindrical surface 15 and/or the generally cylindrical central opening 20 can include a slight taper with respect to the central axis 30, also known as a draft angle. For example, the outer generally cylindrical surface 15 and/or the generally cylindrical central opening 20 can have an inward taper of about one degree with respect to the central axis 30 such that an outer diameter and/or an inner diameter of the one-piece, sloped baffle 10 decreases from the second elliptical end 60 towards the first circular end 50. Various other draft or taper angles are contemplated, such as, for example, inward draft angles of 0.5 degrees, 1.5 degrees, 2 degrees, etc.

An interior surface of the one-piece, sloped baffle 10 includes a plurality of grooves 40 that extend circumferentially therearound. The plurality of grooves 40 aid in diffusing light in a uniform manner along a height of the one-piece, sloped baffle 10. The plurality of grooves 40 is positioned along the height of the one-piece, sloped baffle 10 between the open circular end 50 and the open elliptical end 60 such that substantially all of the interior surface is covered by the plurality of grooves 40 (best shown in FIG. 4). The height of the one-piece, sloped baffle 10 varies in a direction perpendicular to the central axis 30 due to the oblique angle, α, of the open elliptical end 60 (best shown in FIG. 4). The one-piece, sloped baffle 10 has a minimum height h₁ and a maximum height h₂, both of which are a function of the oblique angle, α. The larger the oblique angle, α, the greater the difference height, h₃, between the minimum and maximum heights h₁ and h₂ of the one-piece, sloped baffle 10.

Each one of the plurality of grooves 40 is positioned in a separate plane that is perpendicular to the central axis 30. As best shown in FIGS. 2 and 4, each one of the plurality of grooves 40 located along the minimum height h₁ is substantially uniform and contiguous about the interior surface except for a substantially vertical break or seam along an opening or vertical slot 70. Each of the grooves 40 located along the difference height, h₃, has a shortened circumference as compared to the circumference of the grooves 40 located along the minimum height, h₁, due to the sloped portion (best shown in FIG. 4).

Each one of the grooves 40 has a depth. For example, each one of the grooves 40 can have a depth between about 10 mils and about 90 mils. For another example, each groove can have a depth between about 35 mils and 55 mils. The plurality of grooves 40 can have a range of densities along the height of the one-piece, sloped baffle 10. For example, the plurality of grooves 40 can include between 5 and 20 grooves per linear inch of height of the one-piece, sloped baffle 10. For another example, the plurality of grooves 40 can include between 8 and 12 grooves per linear inch of height of the one-piece, sloped baffle 10. For a groove density of 10 grooves per lineal inch of height and a height of five inches, the one-piece, sloped baffle 10 can include about fifty separate and distinct grooves 40 in total.

While the plurality of grooves 40 is shown and described as covering substantially all of the interior surface from the open circular end 50 to the open elliptical end 60, it is contemplated that the plurality of grooves 40 can extend along a portion of the height of the one-piece, sloped baffle 10. For example, it is contemplated that the plurality of grooves 40 extends along 90 percent (not shown) of the height of the one-piece, sloped baffle 10.

The one-piece, sloped baffle 10 is movable between a resting position (FIG. 1), an expanded position (not shown), and an assembled position (FIG. 6B). A width, w, of the opening 70 changes depending on the position of the one-piece, sloped baffle 10. In the resting position (FIG. 1), the opening 70 has a first width, in the expanded position (not shown), the opening 70 has a second width, and in the assembled position (FIG. 6B), the opening 70 has a third width. The first, second, and third widths are different from one another.

The width, w, of the opening 70 can be increased temporarily when the one-piece, sloped baffle 10 is moved from the resting position to the expanded position during the formation process to aid in removing the one-piece, sloped baffle 10 from a mold (not shown). Additionally, the width, w, of the opening 70 can be decreased (e.g., to about zero inches) when the one-piece, sloped baffle 10 is moved from the resting position to the assembled position during the assembly process of the one-piece, sloped baffle 10 (shown in FIG. 6B).

The opening 70 extends between the open circular end 50 and the open elliptical end 60 (i.e., along the entire minimum height, h₁, of the one-piece, sloped baffle 10). The width, w, of the opening 70 can be a variety of percentages of the circumference of the one-piece, sloped baffle 10 (best shown in FIG. 5) depending on the position of the one-piece, sloped baffle 10. For example, in the resting or expanded position, the width, w, of the opening 70 can be between 0.5 percent and 5 percent of the circumference of the one-piece, sloped baffle 10. For another example, in the assembled position (FIG. 6B), the width, w, of the opening 70 can be between 0 percent and 0.5 percent of the circumference of the one-piece, sloped baffle 10.

For another example, in the resting position, the width, w, of the opening 70 can be about 1.5 percent of the circumference of the one-piece, sloped baffle 10. In such an example, if the outer diameter, D, of the one-piece, sloped baffle 10 is 5.5 inches, the circumference, c, of the one-piece, sloped baffle 10 is calculated using the formula c=π*D, where c is about 17.3 inches. If the opening is 1.5 percent of the circumference, the width, w, is about 0.26 inches. If the width, w, of the opening 70 in the expanded position is two times the width, w, in the resting position, the width, w, of the opening 70 is about 0.5 inches when the one-piece, sloped baffle 10 is in the expanded position. If the width, w, of the opening 70 in the expanded position is three times the width, w, in the resting position, the width, w, of the opening 70 is about 0.75 inches when the one-piece, sloped baffle 10 is in the expanded position. Various other widths, w, of the opening 70 in the resting and expanded positions are contemplated.

The one-piece, sloped baffle 10 includes a pair of opposing edges 72 a,b (best shown in FIGS. 1 and 5). The opposing edges 72 a,b are substantially parallel with the central axis 30 and positioned on opposite sides of the opening 70. The distance between the opposing edges is equal to the width, w, of the opening 70. A first one of the edges 72 a is configured to abut or touch the second one of the edges 72 b, such that the width, w, is about zero inches, in response to the one-piece, sloped baffle 10 being in the assembled positioned (shown in FIG. 6B). Optionally, the first edge 72 a can include a protrusion or rib 74 a that is configured to engage a groove 74 b included in the second edge 72 b in a tongue and groove type connection (best shown in FIG. 5).

First projections or ribs 80 a,b are positioned on opposite sides of the opening 70 and aligned with respective ones of the opposing edges 72 a,b. Specifically, a first one of the first projections 80 a abuts the first edge 72 a such that a portion of the first one of the first projections 80 a forms a portion of the first edge 72 a (best shown in FIG. 5). Similarly, a second one of the first projections 80 b abuts the second edge 72 b such that a portion of the second one of the first projections 80 b forms a portion of the second edge 72 b (best shown in FIG. 5). Alternatively, it is contemplated that the first projections 80 a,b can be set back from the edges 72 a,b a radial distance such that the first projections 80 a,b do not form a portion of the edges 72 a,b.

While the first projections 80 a,b are shown as extending from the open circular end 50 to the elliptical flange 18, it is contemplated that the first projections 80 a,b can extend a shorter distance, such as, for example, 10 percent shorter, 20 percent shorter, 50 percent shorter, etc. While each of the first projections 80 a,b is shown as being a single continuous rib or projection (see FIGS. 1 and 2), it is contemplated that each of the first projections 80 a,b can be formed as a plurality of first projections (not shown), such as, for example, 2 projections, 3 projections, 4 projections, etc.

Second projections or ribs 90 a,b are positioned on opposite sides of the opening 70 at a radial distance from the first projections 80 a,b to form a space or gap 92 a,b between corresponding ones of the first projections 80 a,b and the second projections 90 a,b (best shown in FIGS. 2 and 5). Specifically, a first one of the second projections 90 a is positioned a radial distance in a first direction from the opening 70 such that a space 92 a is formed between the first one of the second projections 90 a and the first one of the first projections 80 a (best shown in FIGS. 2 and 5). Similarly, a second one of the second projections 90 b is positioned a radial distance in a second opposing direction from the opening 70 such that a space 92 b is formed between the second one of the second projections 90 b and the second one of the first projections 80 b (best shown in FIGS. 2 and 5). The spaces 92 a,b provide a place for a tool (not shown) to be inserted when urging the second projections 90 a,b away from one another to expand the opening 70 and thereby enlarge the generally cylindrical opening 20.

The tool used to urge the second projections 90 a,b away from one another can include a portion of a robotic arm. The engaging portion of the tool can include one or more fingers (e.g., a fork-like structure) configured to abut at least a portion of one or more of the second projections 90 a,b in order to exert a force thereon. It is contemplated that the tool includes two or more fingers (e.g., a fork-like structure), one for engaging each of the second projections 90 a,b. The fingers can be spread apart to urge the second projections 90 a,b away from each other. The tool can be controlled manually by an operator of a robotic arm or automatically by one or more processors configured to control movement of the tool. Alternatively, the tool can be a completely manual tool similar to a pair of pliers or the like.

The second projections 90 a,b can be positioned radially along the outer generally cylindrical surface 15 of the one-piece, sloped baffle 10 at a variety of degrees from the opening 70. For example, each of the second projections 90 a,b can be position radially no more than 45 degrees from the opening 70. For another example, each of the second projections 90 a,b can be position radially no more than 30 degrees from the opening 70. For yet another example, each of the second projections 90 a,b can be position radially no more than 15 degrees from the opening 70.

While the second projections 90 a,b are shown as extending from the open circular end 50 to the elliptical flange 18, it is contemplated that the second projections 90 a,b can extend a shorter distance, such as, for example, 10 percent shorter, 20 percent shorter, 50 percent shorter, etc. While each of the second projections 90 a,b is shown as being a single continuous rib or projection (see FIGS. 1 and 2), it is contemplated that each of the second projections 90 a,b can be formed as a plurality of second projections (not shown), such as, for example, 2 projections, 3 projections, 4 projections, etc.

Referring to FIGS. 6A and 6B, a one-piece, sloped baffle assembly 100 includes the one-piece, sloped baffle 10, an elliptical trim ring 110, and at least one fastener 120. As shown in FIG. 6A, the elliptical trim ring 110 is configured to be slid over the one-piece, sloped baffle 10 such that the elliptical trim ring 110 at least partially abuts the elliptical flange 18 of the one-piece, sloped baffle 10. The fastener 120 can be a spring clip or other type of fastening device that is configured to bias the opposing edges 72 a,b of the one-piece, sloped baffle 10 towards one another (best shown in FIG. 6B), reducing the width, w, of the opening 70 to approximately zero inches. That is, the fastener 120 effectively eliminates the opening 70 by biasing the edges 72 a,b such that the first edge 72 a touches the second edge 72 b.

Referring to FIG. 7, a method (200) of forming the one-piece, sloped baffle 10, described above and shown in FIGS. 1-5, using a mold (not shown) includes positioning a cavity portion of the mold adjacent to a core portion of the mold (202). The mold is injected with a material suitable for forming the one-piece, sloped baffle 10 (204). After the material is injected, the material is permitted to set or harden for a predetermined amount of time (206). The material can be allowed to harden between 10 seconds and 3 minutes depending on the type of material.

After the material hardens such that the one-piece, sloped baffle 10 is at least semi-rigid, but still pliable or semi-flexible, the cavity portion of the mold is removed (208) exposing the outer generally cylindrical surface 15 of the one-piece, sloped baffle 10. The plurality of grooves 40 of the one-piece, sloped baffle 10 remain engaged with corresponding projections (not shown) on the core portion of the mold such that the one-piece, sloped baffle 10 cannot be removed from the core portion of the mold in a direction of the central axis 30.

A tool (not shown) is generally positioned in the spaces 92 a,b between the first projections 80 a,b and the second projections 90 a,b proximate the opening 70 of the one-piece, sloped baffle 10 (210). Using the tool, the second projections 90 a,b are urged away from one another to expand or enlarge the opening 70 (212). The expanding and urging causes the one-piece, sloped baffle 10 to be moved from the resting position (FIG. 1) to the expanded position (not shown) wherein the width, w, of the opening 70 is increased. The expanding and urging further causes the generally cylindrical central opening 20 to be enlarged. The enlarging of the generally cylindrical central opening 20 provides clearance for the one-piece, sloped baffle 10 to be removed in the direction of the central axis without damaging or deforming the one-piece, sloped baffle 10. The expanding and urging can cause an inner diameter of the one-piece, sloped baffle 10 to increase by at least one percent and no more than ten percent. For example, the expanding and urging can cause an inner diameter of the one-piece, sloped baffle 10 to increase by about two percent, three percent, or four percent.

The one-piece, sloped baffle 10 is moved in a direction perpendicular to the central axis 30 so as to dislodge the one-piece, sloped baffle 10 from the core portion of the mold (214). Specifically, the one-piece, sloped baffle 10 is moved to disengage the plurality of grooves 40 from the corresponding features (not shown) on an exterior surface of the core portion of the mold. The one-piece, sloped baffle 10 is moved a distance, which is a function of the depth of the grooves 40. The deeper the grooves, the greater the distance that the one-piece, sloped baffle 10 is moved in the direction perpendicular to the central axis 30.

Responsive to the one-piece, sloped baffle 10 being expanded and moved, the one-piece, sloped baffle 10 is removed from the core portion of the mold in a direction of the central axis 30 (216). That is, due to the enlarged central opening 20 and the dislodging of the grooves 40, the one-piece, sloped baffle 10 is permitted to be removed from the core portion of the mold in the direction of the central axis without damaging or deforming the one-piece, sloped baffle 10. It is contemplated that the one-piece, sloped baffle 10 can be moved relative to the core portion of the mold while the mold is held in place or the one-piece, sloped baffle 10 can be held in place by, for example, the tool, while the core portion of the mold is moved in the direction of the central axis 30.

While the method 200 is described as including the acts 202-216, it is contemplated that one or more of these acts is optional. For example, the method 200 can only include the acts of 210-216.

Referring to FIG. 8, a method (300) of assembling the one-piece, sloped baffle assembly 100 described above and shown in FIGS. 6A and 6B using a mold (not shown) can include the acts 202-216 described above in reference to FIG. 7. The method (300) includes biasing the opposing edges 72 a,b of the one-piece, sloped baffle 10 towards one another (302). The biasing can be accomplished manually or via a tool and/or machine, such as, for example, a robotic arm (not shown). The opposing edges 72 a,b can be biased such that the protrusion 74 a at least partially engages the groove 74 b. Responsive to the edge 72 a,b being biased, the fastener 110 is attached to the first projections 80 a,b of the one-piece, sloped baffle 10 (304), as shown in FIG. 6B. Prior or subsequent to attaching the fastener 110, the elliptical trim ring 120 is attached to the one-piece, sloped baffle 10. The elliptical trim ring 120 is generally slid over the one-piece, sloped baffle 10 from the open circular end 50 towards the open elliptical end 60 such that the elliptical trim ring 120 at least partially abuts the elliptical flange 18 of the one-piece, sloped baffle 10, as shown in FIG. 6B.

While the one-piece, sloped baffle 10 is described above and shown in the FIGS. as having a sloped bottom portion with the open elliptical end 60, it is contemplated that the one-piece, sloped baffle 10 can instead be a cylindrical baffle (not shown). The cylindrical baffle includes an open circular top end, an open circular bottom end, and a generally cylindrical central opening having a central axis extending between the ends of the cylindrical baffle. According to such an alternative, the top and bottom ends are each defined by a plane that is perpendicular to the central axis of the cylindrical baffle. The cylindrical baffle includes an opening extending between the ends in the same, or similar, manner at the opening 70. Additionally, the cylindrical baffle includes first projections positioned on opposite sides of the opening in abutting relationship thereto and the cylindrical baffle further including at least one groove beginning on one side of the opening, extending circumferentially around an inner surface of the cylindrical baffle, and ending on the other side of the opening in the same, or similar, manner as the grooves 40. The methods of forming (200) and assembling (300) described above in reference to FIGS. 7 and 8 can similarly be applied to a cylindrical baffle.

Words of degree such as “substantially” or “about” are used herein in the sense of “at, or nearly at, given the process, control, and material limitations inherent in the stated circumstances” and are used herein to keep the unscrupulous infringer from taking advantage of unqualified or absolute values stated for exemplary embodiments.

While particular embodiments and applications of the present disclosure have been illustrated and described, it is to be understood that the disclosure is not limited to the precise construction and compositions disclosed herein and that various modifications, changes, and variations may be apparent from the foregoing descriptions without departing from the spirit and scope of the disclosure as defined in the appended claims. 

What is claimed is:
 1. A one-piece, sloped baffle for use in a lighting fixture configured to be installed in a sloped structure, the baffle comprising: a generally cylindrical central opening having a central axis extending between an open circular end and an open elliptical end, a plane defining the open circular end being perpendicular to the central axis, a plane defining the open elliptical end being at an oblique angle relative to the central axis; an opening extending between the ends; a pair of opposing edges substantially parallel with the central axis and on opposite sides of the opening; first projections positioned on opposite sides of the opening and aligned with the opposing edges; second projections positioned on opposite sides of the opening at a radial distance from the first projections; and a plurality of grooves extending circumferentially around an inner surface of the baffle.
 2. The one-piece, sloped baffle of claim 1, further comprising an elliptical flange at the open elliptical end of the baffle.
 3. The one-piece, sloped baffle of claim 2, wherein each of the first projections extends from the open circular end to the elliptical flange.
 4. The one-piece, sloped baffle of claim 2, wherein each of the second projections extends from the open circular end to the elliptical flange.
 5. The one-piece, sloped baffle of claim 1, wherein each one of the second projections is positioned radially no more than 45 degrees from the opening.
 6. The one-piece, sloped baffle of claim 1, wherein one of the opposing edges includes a protrusion configured to engage a corresponding groove formed in the other of the opposing edges.
 7. The one-piece, sloped baffle of claim 1, wherein the plurality of grooves is positioned along a height of the baffle between the ends, each of the grooves lying in a separate plane perpendicular to the central axis.
 8. The one-piece, sloped baffle of claim 1, wherein the baffle is configured to be moved between a resting position wherein the opening has a first width, an expanded position wherein the opening has a second width, and an assembled position wherein the opening has a third width, the first, second, and third widths being different. 